PV module mounting assembly with clamp / standoff arrangement

Abstract

A mounting assembly for use in mid-grab and/or edge-grab applications may include a clamp secured to a stanchion by a clamp fastener. The mounting assembly may also include a mounting plate and a base plate that may be secured to a mounting device by the stanchion. The mounting assembly may be used, for example, to secure photovoltaic modules (or other devices or structures) of varying heights to a roof or other building surface and to provide increased lift-off resistance.

What is claimed is: 
     
         1 . A mounting system to secure a photovoltaic module to a building surface, comprising:
 a clamp, comprising:
 an upper wall comprising a fastener aperture, a first long edge on one side of the fastener aperture, and a second long edge approximately parallel to the first long edge and on an opposite side of the fastener aperture; 
 a first sidewall extending from a lower surface of the upper wall, the first sidewall spaced from the first long edge to form a first clamping section configured to engage the photovoltaic module, the first clamping section comprising a lower clamp surface; 
 a plurality of teeth formed in the lower clamp surface, wherein the teeth increase in size from an inner portion of the lower clamp surface proximate to the first sidewall to a distal end of the lower clamp surface such that an innermost tooth has a minimum height measured in a vertical dimension and an outermost tooth has a maximum height measured in the vertical dimension, the maximum height being greater than the minimum height; and 
 a second sidewall extending from the lower surface of the upper wall, the first and second sidewalls defining a stanchion receptacle therebetween; 
   a stanchion comprising a body, a first threaded shaft extending from a first end of the body, and a first threaded hole extending through a second end of the body, the first end of the body being opposite the second end of the body;   a base plate, comprising:
 a body with a first narrow end and a second narrow end opposite to the first narrow end; 
 a first surface of the body; 
 a second surface of the body opposite to the first surface, the first and second surfaces extending in a longitudinal dimension from the first narrow end to the second narrow end; 
 a first flange and a second flange extending from the first surface between the first and second narrow ends, the first flange comprising a first inner surface facing a second inner surface of the second flange, wherein the first inner surface is separated from the second inner surface by a first interior width measured in a lateral dimension that is orthogonal to the longitudinal dimension; 
 a third flange and a fourth flange extending from the second surface between the first and second narrow ends, the third flange comprising a third inner surface facing a fourth inner surface of the fourth flange, wherein the third inner surface is separated from the fourth inner surface by a second interior width measured in the lateral dimension that is greater than the first interior width; and 
 a plate aperture extending through the first and second surfaces, the plate aperture comprising a diameter sufficient to receive the first threaded shaft of the stanchion; 
   a mounting device comprising a second hole configured to receive the first threaded shaft of the stanchion to releasably secure the base plate between the stanchion and the mounting device, the mounting device configured to engage a projection extending from the building surface; and   a clamping fastener comprising a second threaded shaft configured to threadably engage the first threaded hole of the stanchion, wherein the fastener aperture of the clamp and the first threaded hole of the stanchion are configured to receive the second threaded shaft of the clamping fastener to selectively secure the clamp to the stanchion with at least a portion of the stanchion body extending into the stanchion receptacle.   
     
     
         2 . The mounting system of  claim 1 , wherein a horizontal reference plane contacting a distal point of the innermost tooth extends through the outermost tooth proximate to a base of the outermost tooth, the horizontal reference plane extending in the longitudinal dimension and the lateral dimension. 
     
     
         3 . The mounting system of  claim 1 , wherein the third flange is offset in the lateral dimension from the first flange such that a vertical reference plane defined by the third inner surface does not intersect the first flange, the vertical reference plane extending in the longitudinal dimension and the vertical dimension. 
     
     
         4 . The mounting system of  claim 1 , wherein the base plate further comprises serrations formed on one or more of the first inner surface of the first flange, the second inner surface of the second flange, the third inner surface of the third flange, and the fourth inner surface of the fourth flange. 
     
     
         5 . The mounting system of  claim 1 , further comprising a mounting plate, comprising:
 a top surface oriented toward the photovoltaic module when the photovoltaic module is secured to the building surface;   a bottom surface opposite the top surface; and   a mounting aperture with a diameter sufficient to receive the first threaded shaft of the stanchion.   
     
     
         6 . The mounting system of  claim 1 , wherein the lower clamp surface of the first clamping section further comprises a flat portion positioned between the innermost tooth of the teeth and the first sidewall. 
     
     
         7 . The mounting system of  claim 6 , wherein the innermost tooth is spaced from an exterior surface of the first sidewall by a predetermined distance. 
     
     
         8 . The mounting system of  claim 1 , wherein:
 in a first configuration of the mounting system to engage a first photovoltaic module of a first size, the first surface of the base plate is oriented toward the clamp such that the second surface of the base plate is facing the mounting device; and   in a second configuration of the mounting system to engage a second photovoltaic module of a second size that is different than the first size, the second surface of the base plate is oriented toward the clamp such that the first surface of the base plate is facing the mounting device.   
     
     
         9 . A clamp for a mounting system to secure a photovoltaic module to a building surface, comprising:
 an upper wall comprising a fastener aperture, a first long edge on one side of the fastener aperture, and a second long edge approximately parallel to the first long edge, the second long edge on an opposite side of the fastener aperture, the first and second long edges extending in a longitudinal dimension;   a first sidewall extending from a lower surface of the upper wall, the first sidewall positioned between the fastener aperture and the first long edge to form a first clamping section configured to engage the photovoltaic module, the first clamping section comprising a lower clamp surface;   a plurality of teeth formed in the lower clamp surface, wherein the teeth increase in size from an inner portion of the lower clamp surface proximate to the first sidewall to a distal end of the lower clamp surface such that:
 an innermost tooth has a minimum height measured in a vertical dimension between a base and a distal point of the innermost tooth, the vertical dimension being perpendicular to the longitudinal dimension; and 
 an outermost tooth has a maximum height measured in the vertical dimension, the maximum height being greater than the minimum height; and 
   a second sidewall extending from the lower surface of the upper wall, the first and second sidewalls defining a stanchion receptacle therebetween.   
     
     
         10 . The clamp of  claim 9 , wherein a horizontal reference plane contacting the distal point of the innermost tooth extends through the outermost tooth, the horizontal reference plane extending in the longitudinal dimension and a lateral dimension perpendicular to the longitudinal dimension. 
     
     
         11 . The clamp of  claim 9 , wherein the fastener aperture is circular and unthreaded, and wherein the fastener aperture is the only aperture through the upper wall. 
     
     
         12 . A base plate for a mounting system to secure a photovoltaic module to a building surface, comprising:
 a body with a first narrow end and a second narrow end opposite to the first narrow end;   a first surface of the body;   a second surface of the body opposite to the first surface, the first and second surfaces extending in a longitudinal dimension from the first narrow end to the second narrow end;   a first flange and a second flange extending from the first surface between the first and second narrow ends, the first flange comprising a first inner surface facing a second inner surface of the second flange, wherein the first inner surface is separated from the second inner surface by a first interior width measured in a lateral dimension that is orthogonal to the longitudinal dimension;   a third flange and a fourth flange extending from the second surface between the first and second narrow ends, the third flange comprising a third inner surface facing a fourth inner surface of the fourth flange, wherein the third inner surface is separated from the fourth inner surface by a second interior width measured in the lateral dimension that is greater than the first interior width, and wherein a portion of one or more of the first inner surface, the second inner surface, the third inner surface, and the fourth inner surface comprises serrations; and   a plate aperture extending through the first and second surfaces.   
     
     
         13 . The base plate of  claim 12 , wherein the third flange is offset in the lateral dimension from the first flange such that a first vertical reference plane defined by the third inner surface does not intersect the first flange, the first vertical reference plane extending in the longitudinal dimension and a vertical dimension that is orthogonal to the longitudinal dimension, and wherein the fourth flange is offset in the lateral dimension from the second flange such that a second vertical reference plane defined by the fourth inner surface does not intersect the second flange, the second vertical reference plane extending in the longitudinal dimension and the vertical dimension and being approximately parallel to the first vertical reference plane. 
     
     
         14 . The base plate of  claim 13 , wherein the first and second flanges are positioned between the first and second vertical reference planes. 
     
     
         15 . The base plate of  claim 12 , wherein the serrations formed on the inner surface of the first flange extend in the longitudinal dimension and are oriented approximately parallel to the first surface. 
     
     
         16 . The base plate of  claim 12 , wherein the base plate is formed of a single piece of extruded metal. 
     
     
         17 . The base plate of  claim 12 , wherein the first flange extends continuously for an entire length of the base plate from the first narrow end to the second narrow end. 
     
     
         18 . The base plate of  claim 12 , wherein the first inner surface, the second inner surface, the third inner surface, and the fourth inner surface are oriented approximately parallel to one another. 
     
     
         19 . The base plate of  claim 12 , wherein the first surface is substantially planar between the first and second narrow ends and between the first and second inner surfaces. 
     
     
         20 . The base plate of  claim 12 , wherein the plate aperture is circular and unthreaded.